SUMMER INTERNSHIP REPORT

ON

“Insights into
Infrastructure &Town Planning Practices”
Town Planning Department
Rourkela Steel Plant (SAIL), Rourkela

Submitted by
Pratyus Senapati
Regd. No. 2202030007
4th Year – 7th Semester

Submitted to
Dr. Laxmipriya Mohanty
Assistant Professor
Department of Civil Engineering

Veer Surendra Sai University of Technology, Burla

Sambalpur-768018.Odisha
 DECLARATION

I hereby declare that the Summer Internship Report

titled “Insights into Infrastructure &Town Planning
Practices” submitted to Dr. Laxmipriya Mohanty,
Assistant Professor, Department of Civil
Engineering is a record of the internship training done
by me at Town Planning Department Rourkela Steel
Plant (SAIL), Rourkela, under the guidance of faculty
members of Town Planning Department, RSP,
Rourkela during the period 10th May 2024 to 9th June
2025.
This report is submitted in partial fulfillment of the
requirements for the Seminar on Internship in 7th
Semester of Bachelor of Technology in Civil
Engineering.
All the work presented in this report and references
used have been duly acknowledged and the facts and
findings are true to the best of my knowledge.

Pratyus Senapati
Regd No: 2202030007
Year 4th Semester 7th
Department of Civil Engineering
 ACKNOWLEDGEMENT

I would like to extend my gratitude to Town Planning

Dept., RSP Rourkela for providing opportunity to study
and analyse the detailed 'Panorama 2021' document.
Their cooperation, guidance, and valuable insights have
been instrumental in preparing this comprehensive
report. We also thank the HRD Centre for compiling
and making available such an informative resource.
I am deeply thankful to my departmental mentors and
officials for their constant guidance, encouragement,
and for sharing their technical expertise throughout the
course of my training. Their insights into urban
planning, infrastructure development, and township
management have enriched my knowledge and
broadened my perspective.
I would also like to extend my appreciation to the staff
members of the department for their cooperation and
support, which made my internship a truly engaging
and rewarding learning experience.

Role: Town Planning Intern

 CONTENTS

TITLE PAGE NO
1. Introduction…….………………………………...01 - 03
(i) Executive Summary……………….…………………01
(ii) Overview of Rourkela Steel Plant.……………..........01
2. Department-Wise Analysis......…...……………........02
3. Key Production Processes… ………………….........03
4. Major Milestones……………………………….…...04
5. Project Overview.........................................................05
(i) Ground Floor Plan....................................................05
(ii) First Floor Plan........................................................06
(iii) Key Components....................................................06
6. Site Execution Activities &On-Site Observations....07
7. Key Skills Developed...................................................08
8. Performance Analysis……………………...…...…....09
9.Conclusion…..………………………………………...10
10. References...……………………………........11
11. Certification………………………………………....12
 INTRODUCTION

Executive Summary
Rourkela Steel Plant (RSP), a unit of Steel Authority of India
Limited (SAIL), is the first integrated steel plant in the public
sector in India. It was set up with German collaboration in
1955 and is located in Rourkela, Odisha. The Town
Engineering Department of RSP handles all civil, electrical
and infrastructure development works including educational
institutions like Kendriya Vidyalaya.
This report provides an analytical overview of its operations,
infrastructure, production capacity, technological
advancements, and achievements as outlined in 'Panorama
2021'. The plant's diverse departments, from raw material
handling to specialized rolling mills, demonstrate its
comprehensive capabilities in steel production.

Overview of Rourkela Steel Plant

It is the first integrated steel plant under Hindustan Steel
Limited, in collaboration with leading steelmakers from
Germany.
Initially commissioned with a capacity of 1.0 MTPA, it has
undergone several phases of expansion and modernization,
currently boasting a capacity of: 4.5 MTPA of Hot Metal, 3.7
MTPA of Crude Steel, 3.49 MTPA of Saleable Steel.
It produces a wide range of steel products including plates,
hot rolled coils, cold rolled sheets, galvanized sheets, silicon
steel, ERW and spiral welded pipes.
01
 DEPARTMENT-WISE ANALYSIS

• Raw Material Handling Plant - Efficient handling and

preparation of iron ore, fluxes, and coke for production.
• Coke Ovens - Conversion of blended coking coal into
metallurgical coke and recovery of by-products.
• Coal Chemicals - Recovery of tar, ammonia, benzol,
sulphuric acid, and other valuable chemicals from coke
oven gas.
• Sintering Plants - Agglomeration of iron ore fines into
sinter for blast furnace feed.
• Blast Furnaces - Smelting of iron ore to produce hot metal
using coke as a reductant.

• Steel Melting Shops - Conversion of hot metal into steel

via LD process, continuous casting into slabs.
• Plate and Hot Strip Mills - Rolling slabs into plates, coils,
and strips of various grades and thicknesses.
• Cold Rolling and Silicon Steel Mills - Production of CR
sheets, galvanized sheets, and electrical grade silicon steel.
• Pipe Plants - Manufacturing ERW and spiral welded pipes
for industrial applications.
• Auxiliary Units - Power generation, water management,
maintenance, safety, and environmental engineering.

02
 KEY PRODUCTION PROCESSES

1. Raw Material Handling and Base Mix

Preparation: Ensures consistent quality feed for
sintering.

2. Coke Production and Dry Cooling: Produces strong

metallurgical coke while recovering waste heat.

3. Sintering: Utilizes iron ore fines, fluxes, and coke

breeze to produce porous sinter.

4. Blast Furnace Operation: Reduces iron ore to

molten hot metal.

5. Steelmaking in LD Converters: Converts hot metal

to steel, followed by continuous casting.

6. Rolling Mills: Convert slabs into final steel products.

7. By-product Recovery: Captures valuable chemicals

and reduces environmental impact

03
 MAJOR MILESTONES

• 1959 - First blast furnace commissioned and hot

metal production started.

• 1960s - Commissioning of plate mill, hot strip mill,

pipe plants.

• 1988-1999 - First modernization phases completed,

enhancing production capacity.

• 2013-2015 - Expansion projects completed,

commissioning of new blast furnace, plate mill, and
sintering units.

• 2021 - Surpassed 100 million tonnes of cumulative

hot metal production.

04
 PROJECT OVERVIEW

• Project: Construction of Two-Floor Building

Extension at Kendriya Vidyalaya.
• Scope: - 2 Classrooms on Ground Floor
- 2 Classrooms on First Floor
• Purpose: To expand academic infrastructure in the
school premises.
• Client: Kendriya Vidyalaya Sangathan
• Location: Kendriya Vidyalaya, Rourkela
• Architectural & Structural Layout
• Ground Floor Plan:
- Two classrooms of 9125 mm x 7800 mm.
- Corridor access from the front.

05
 • First Floor Plan:
- Mirrors the ground floor
- Staircase is accessible from old building.

Key Components:
Multiple entry/exit points to classrooms.
Column Thickness Variation:
Columns vary in thickness depending on their load-
bearing responsibility - central columns typically
thicker to support greater axial loads.
Cantilever Beam:
Provided at corridor edges to support projection and
ensure unobstructed movement space below without
requiring vertical supports.

06
 Site Execution Activities &
On-Site Observations

- Excavation, foundation work, column starters.

- Layout marking and shuttering inspection.

- Material staging.

- Concrete mixing and compaction observed.

- Water Curing process followed after casting.

07
 KEY SKILLS DEVELOPED

TECHNICAL SKILLS:
- Plan reading
- Layout understanding
- Column and cantilever beam function.

PROJECT MANAGEMENT:
- Department coordination
- Progress tracking.

SOFT SKILLS:
- Team communication
- Field supervision.

08
 PERFORMANCE ANALYSIS

RSP's continuous modernization and adoption of energy-

efficient technologies have significantly improved
production capacity, product quality, and environmental
performance.

The plant's diverse product range meets both domestic

and international market demands. Investments in
pollution control, waste heat recovery, and by-product
utilization have reduced operational costs and minimized
environmental impact.

09
 CONCLUSION

The 'Panorama 2021' document reflects Rourkela Steel

Plant’s remarkable journey of growth, technological
advancement, and contribution to the steel industry in
India.

With sustained focus on modernization, energy

efficiency, and quality, RSP is well-positioned to meet
future challenges and opportunities in the global steel
market.

10
 REFERENCES
____________________________________________________________________________________________________

• Rourkela Steel Plant – Official Website. Steel

Authority of India Limited (SAIL). Retrieved from:
https://sail.co.in/rsp

• Town Planning Department, Rourkela Steel Plant –

Internal Training Materials and Discussions (2025).

• Ministry of Steel, Government of India. Steel

Industry Overview. Retrieved from:
https://steel.gov.in

• Rangwala, S.C. (2013). Town Planning. Charotar

Publishing House Pvt. Ltd.

• Relevant site visits, observations, and practical

learning during internship at Town Planning
Department, RSP (2025).

11
CERTIFICATION